Anti-microbial decorative laminate

ABSTRACT

A decorative laminate is disclosed, including a first laminate layer containing an anti-microbial agent and a second laminate layer. A decorative layer is disposed selectively between the first laminate layer and the second laminate layer. The first and second laminate layers include a thermoplastic fluoropolymer material. The first laminate layer, the decorative layer, and the second laminate layer are laminated together to form the decorative laminate, which is configured for application to a structural component.

FIELD

This disclosure relates to laminates and methods for making laminates.More specifically, the disclosed examples relate to decorativelaminates.

INTRODUCTION

Decorative laminates are used in a wide variety of applications,including for surfaces of walls, countertops, and other structures, suchas interior structural components of aircraft. For example, decorativelaminates may be applied to the surfaces of such aircraft interiorstructural components as cabin interior sidewall and ceiling panels,floor panels, stowage bins, lavatory and galley panels and structures,bulkhead partitions, window shades, and other aircraft interiorstructural components.

During the course of typical usage, people may contact the aircraftinterior surfaces and transfer bacteria or other microbial traces to thedecorative laminates. Additionally, luggage, food products, non-sterileair, etc. may transfer microbial traces or substances promotingmicroorganism growth. Inhibiting such growth and/or eliminating suchmicroorganisms is desirable to improve cleanliness and prevent spread ofmicroorganisms. Some anti-microbial paints are used for this purpose,but are aesthetically and functionally limited, and may obscure designelements when applied to decorative laminate. Graphics or complexpatterns applied in paint may lack durability and be difficult and/orexpensive to produce.

SUMMARY

The present disclosure provides systems, apparatuses, and methodsrelating to anti-microbial decorative laminates. In some examples, adecorative laminate can include a first laminate layer containing ananti-microbial agent and a second laminate layer. A decorative layer maybe disposed selectively between the first laminate layer and the secondlaminate layer. The first and second laminate layers can include athermoplastic fluoropolymer material. The first laminate layer, thedecorative layer, and the second laminate layer can be laminatedtogether to form the decorative laminate, which may be configured forapplication to a structural component.

In some examples, a decorative laminate system can include a structuralcomponent with a bonding surface and a decorative laminate applied tothe bonding surface. The decorative laminate can include a firstlaminate layer with a transparent appearance that contains ananti-microbial agent, and a second laminate layer with an opaqueappearance. The first and second laminate layers can include athermoplastic fluoropolymer material, and a decorative layer can bedisposed between the first and second laminate layers. The decorativelaminate can further include a resin layer disposed on the secondlaminate layer, and an adhesive layer disposed between the decorativelaminate and the bonding surface of the structural component.

In some examples, a vehicle can include a structural component and adecorative laminate applied to the structural component. The decorativelaminate can include a first laminate layer containing an anti-microbialagent, a second laminate layer, and a decorative layer disposed betweenthe first and second laminate layers. The first and second laminatelayers can include a thermoplastic fluoropolymer material. The firstlaminate layer, the decorative layer, and the second laminate layer canbe laminated together to form the decorative laminate.

Features, functions, and advantages may be achieved independently invarious examples of the present disclosure, or may be combined in yetother examples, further details of which can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an illustrative anti-microbialdecorative laminate in accordance with aspects of the presentdisclosure.

FIG. 2 is an illustration of a cabin interior of an aircraft thatincludes an anti-microbial decorative laminate according to the presentteachings.

FIG. 3A is an exploded side view of an illustrative anti-microbialdecorative laminate.

FIG. 3B is an assembled side view of the laminate of FIG. 3A.

FIG. 4A is an exploded side view of another illustrative anti-microbialdecorative laminate.

FIG. 4B is an assembled side view of the laminate of FIG. 4A.

FIG. 5A is an exploded side view of another illustrative anti-microbialdecorative laminate.

FIG. 5B is an assembled side view of the laminate of FIG. 5A.

FIG. 6 is a front perspective view of assembled structural compositepanels, each including an applied anti-microbial decorative laminatewith a positional system pattern.

FIG. 7A is a front perspective view of an aircraft interior structuralcomponent with applied anti-microbial decorative laminate with first andsecond decorative themes.

FIG. 7B is a front perspective view of the structural component of FIG.7A, exposed to a light source.

FIG. 8 is a flow chart depicting steps of an illustrative method formaking anti-microbial decorative laminate according to the presentteachings.

FIG. 9 is a flowchart depicting steps of an illustrative aircraftmanufacturing and service method.

FIG. 10 is a schematic diagram of an illustrative aircraft.

DETAILED DESCRIPTION

Various aspects and examples of an anti-microbial decorative laminate,are described below and illustrated in the associated drawings. Unlessotherwise specified, a decorative laminate in accordance with thepresent teachings, and/or its various components may, but are notrequired to, contain at least one of the structures, components,functionalities, and/or variations described, illustrated, and/orincorporated herein. Furthermore, unless specifically excluded, theprocess steps, structures, components, functionalities, and/orvariations described, illustrated, and/or incorporated herein inconnection with the present teachings may be included in other similardevices and methods, including being interchangeable between disclosedexamples. The following description of various examples is merelyillustrative in nature and is in no way intended to limit thedisclosure, its application, or uses. Additionally, the advantagesprovided by the examples and examples described below are illustrativein nature and not all examples and examples provide the same advantagesor the same degree of advantages.

This Detailed Description includes the following sections, which followimmediately below: (1) Overview; (2) Examples, Components, andAlternatives; (3) Advantages, Features, and Benefits; and (4)Conclusion. The Examples, Components, and

Alternatives section is further divided into subsections A through G,each of which is labeled accordingly.

Overview

In general, an antimicrobial decorative laminate can include adecorative layer selectively disposed between an inner layer and anouter layer including an anti-microbial material. The outer layer can betransparent, and the inner layer can be semi-transparent or opaque. Thedecorative layer can include visible and/or light-activated materialsarranged in a decorative and/or functional pattern. The laminate can beconfigured for application to a structure or structural component. FIG.1 is a schematic diagram of an illustrative anti-microbial decorativelaminate 10 applied to a structure 28.

Decorative laminate 10 includes a first layer 62 a, a decorative layer76, and a second layer 62 b. Decorative layer 76 is selectively disposedbetween the first and second layers. As shown in FIG. 1, selectivelydisposed may be understood to mean that decorative layer 76 is disposedbetween first layer 62 a and second layer 62 b in some portions ofdecorative laminate 10, and is not disposed between the first and secondlayers in other portions of the decorative laminate. The first layer 62a, decorative layer 76, and second layer 62 b can be laminated togetherto form decorative laminate 10.

Decorative layer 76 may include any inks, pigments, or other visiblematerials. For example, the decorative layer may be an ink patternprinted onto second layer 62 b. The decorative layer can additionally oralternatively include light activated materials, as described in U.S.Pat. No. 9,718,302 which is hereby incorporated by reference in itsentirety for all purposes. For instance, the decorative layer caninclude an ultraviolet (UV) activated pigment that is non-visible untilexposed to a source of UV light. The decorative layer can be depositedin a decorative and/or functional pattern. For example, the layer caninclude a manufacturer logo, a barcode, and/or an alignment pattern thatfacilitates alignment of decorative laminate 10 during application tostructure 28.

Second layer 62 b includes a thermoplastic fluoropolymer material. Inparticular, the second layer can be a polyvinylidene fluoride film, anintegral color polyvinyl fluoride film and/or a polyvinyl fluoride filmadhered to an aluminum foil. The second layer can be opaque.

First layer 62 a has a first side 64 a and a second side 64 b. Firstside 64 a can be described as facing away from structure 28, whendecorative laminate 10 is applied to the structure. Second side 64 b cancontact and/or face decorative layer 76. First layer 62 a can beoptically transparent, allowing decorative layer 76 to be visible. Firstlayer 62 a can also be transparent to ultraviolet (UV) and/or infrared(IR) light, allowing such light incident on the first layer to penetrateto decorative layer 76 and affect any light-activated materials.

First layer 62 a includes a thermoplastic fluoropolymer material 74, andan anti-microbial agent 81. The anti-microbial agent can include anyeffective chemical agents, biological agents, and/or combinations ofagents, including but not limited to bacteriostatic agents, fungistaticagents, antibiotic agents, and fungicides. For example, theanti-microbial agent can be a metal such as silver, copper, zirconium,sodium, potassium, and/or any combination thereof. As another example,the anti-microbial agent can be a phenolic such as para-tert-amylphenol(PTAP).

The anti-microbial agent 81 and thermoplastic fluoropolymer material 74of first layer 62 a can be incorporated, adhered, aggregated, orotherwise combined to form the first layer in any effective manner. Theanti-microbial agent can be homogenously distributed throughout thepolymer material, can be localized proximate first side 64 a of thefirst layer, and/or can be disposed according to some pattern. Theanti-microbial agent can be distributed according to effects of amanufacturing process. In the depicted example, microbial agent 81 isdispersed in thermoplastic fluoropolymer material 74 with a higherconcentration toward first side 64 a of first layer 62 a. Such adistribution can provide desired anti-microbial effects while minimizingthe required quantity of microbial agent 81.

The anti-microbial agent 81 and the polymer material can be combined insuch a manner as to achieve a desired transparency of first layer 62 a.For example, metal agents can be finely powdered, to minimize visualdefects. In one specific possible example, the anti-microbial agent caninclude metal powder with a median particle size on the order of onemicrometer, one nanometer, or some other size scale that minimizesvisibility of the powder or that provides some other desiredcharacteristic.

First layer 62 a can be a metal-polymer nanocomposite (MPN). Powderedmetal such as silver can be co-deposited with a thermoplasticfluoropolymer such as polyvinylidene fluoride to achieve a particulatepolymer composite. A filling ratio and microstructure properties such assize, size distribution, and inter-cluster separation may be selected toprovide desired optical, UV, and/or IR transmission. First layer 62 acan include a particulate or dispersoid polymer composite with powderedmetal on either a micro or macro scale.

Anti-microbial agent 81 can be deposited on first surface 64 a of firstlayer 62 a. For instance, a phenolic compound in solution can beuniformly coated onto the first layer. Alternatively, powdered metalsuspended in a transparent ink can be printed onto first layer 62 a in agrid pattern that provides effective anti-microbial coverage whilepreserving desired transparency of first layer 62 a.

Anti-microbial agent 81 can be combined with the polymer material toform first layer 62 a prior to lamination of the first layer to formdecorative laminate 10. Anti-microbial agent 81 can be combined with thepolymer material of first layer 62 a subsequent to lamination of thefirst layer to form decorative laminate 10.

The decorative laminate 10 can further include additional layersdisposed between the first layer and the decorative layer, between thedecorative layer and the second layer, and/or between the second layerand the structure. Additional layers can include, for example, one ormore of a resin layer, a polymer laminate layer, a decorative layer,and/or an adhesive layer.

First layer 62 a can be described as an outer-most layer, disposed at agreatest distance from structure 28 when decorative laminate 10 isapplied to the structure. Anti-microbial agent 81 can be disposed atfirst side 64 a and/or on first side 64 a of first layer 62 a, which canbe described as an outer surface of decorative laminate 10. In otherwords, when decorative laminate 10 is applied to structure 28,microorganisms contacting the decorative laminate can contact first side64 a of first layer 62 a and anti-microbial agent 81.

A decorative laminate system can include decorative laminate 10 and oneor more structures 28. A vehicle can include structures 28 and applieddecorative laminate 10. Decorative laminate 10 can be applied to thestructure, structural component, and/or structural composite panel ofany vehicle and/or building. For example, the decorative laminate can beapplied to an interior structural component of an aircraft, rotorcraft,spacecraft, watercraft, automobile, or truck. Decorative laminate alsocan be applied to interior structural components of a building such asbathroom counters, stall partitions, floors, informational signage,and/or doors. Generally speaking, it can be desirable to applyanti-microbial decorative laminates to any surface or structuralcomponent where microorganisms may be found.

FIG. 2 shows an illustrative cabin interior of an air vehicle 12,including structural components 28 covered with one or more examples ofan anti-microbial decorative laminate as disclosed herein, such asdecorative laminate 10. The structural components 28 include cabininterior sidewall 13 and ceiling panels 14, floor panels 15, stowagebins 16, and window shades 17. Other structural components of airvehicle 12 including, but not limited to insulation barriers, moisturebarriers, composite noise panels, lavatory and galley panels andstructures, bulkhead partitions, and cargo bin liners can be covered byan anti-microbial decorative laminate according to the presentteachings.

Examples, Components, and Alternatives

The following sections describe selected aspects of exemplaryanti-microbial decorative laminates as well as related systems and/ormethods. The examples in these sections are intended for illustrationand should not be interpreted as limiting the entire scope of thepresent disclosure. Each section may include one or more distinctembodiments or examples, and/or contextual or related information,function, and/or structure.

A. Illustrative Anti-Microbial Decorative Laminate

As shown in FIGS. 3A-3B, this section describes an illustrativedecorative laminate 110. Decorative laminate 110 is an example ofanti-microbial decorative laminate 10, as described above. FIG. 3A is anexploded side view of decorative laminate 110, and FIG. 3B is anassembled side view of the decorative laminate. As shown, decorativelaminate 110 comprises multiple laminate layers 162, including at leasta first laminate layer 162 a and a second laminate layer 162 b.Depending on the decorative laminate 110 desired to be made, one or moreadditional laminate layers 162 can be included.

As further shown in FIG. 3A, the first laminate layer 162 a has a firstside 164 a and a second side 164 b. The first laminate layer 162 a has atransparent appearance 168 or clear appearance, in that it will transmitlight through it.

The laminate layers 162 can have a thickness in a range of from about0.25 mil to about 5.0 mils, although other suitable thicknesses may beused. The first laminate layer 162 a can have a thickness between about1.0 mil to about 2.0 mils. Selecting a thickness within this range canpromote the transparent appearance 168 of first laminate layer 162 a,thereby allowing clear display of a decorative image or images. Thesecond laminate layer 162 b, and any additional laminate layers 162, caneach have a thickness between about 2.0 mil to about 4.0 mils. Selectinga thickness within this range can allow use of lower-cost, widelyavailable laminate layers, and facilitate manufacture of the decorativelaminate.

In the present example, the first laminate layer 162 a is comprised of ametal-polymer nanocomposite (MPN) of silver and polyvinyl fluoride(PVF). Nanoparticles of powdered silver 181 are homogenously dispersedthroughout a thermoplastic fluoropolymer material 174, such as apolyvinyl fluoride (PVF) film. The nanoparticle concentration and/orfill ratio can be selected to maximize anti-microbial properties offirst laminate layer 162 a, but maintain desired transparency.

In the present example, the second laminate layer 162 b is alsocomprised of a thermoplastic fluoropolymer material 174. Thethermoplastic fluoropolymer material 174 can include a polyvinylfluoride (PVF) film, polyvinylidene fluoride (PVDF) film, integral colorpolyvinyl fluoride (PVF) film, a polyvinyl fluoride (PVF) film/aluminumfoil/adhesive material, or another suitable thermoplastic fluoropolymermaterial.

A polyvinyl fluoride (PVF) film that can be used is commerciallyavailable from E.I. DuPont De Nemours and Company (Wilmington, Del.)under the designation TEDLAR. (TEDLAR is a registered trademark of E.I.DuPont De Nemours and Company of Wilmington, Del.) A polyvinylidenefluoride (PVDF) film that can be used is commercially available fromAvery Dennison Corporation (Glendale, Calif.) under the designationAVIMARK. (AVIMARK is a trademark of Avery Dennison Corporation ofGlendale, Calif.)

The integral color polyvinyl fluoride (PVF) film comprises polyvinylfluoride (PVF) film with decorative color incorporated into the PVFfilm. The polyvinyl fluoride (PVF) film/aluminum foil/adhesive materialcomprises a PVF film having an opaque appearance 172 combined with 0.7mil aluminum foil combined with an adhesive material.

Polyvinyl fluoride materials are advantageous for the laminate layers162 due to their physical toughness, chemical inertness, abrasionresistance, and consistent performance regardless of temperaturechanges. The polyvinyl fluoride materials are also able to receive awide variety of inks used for printing graphics. As used herein, theterm “thermoplastic fluoropolymer material” refers to polyvinylfluoride-based materials including polyvinyl fluoride polymers (i.e.,polymer formed from vinyl fluoride). The fluorinated polymer isgenerally a polymer, copolymer, or terpolymer of vinyl fluoride.

Laminate layers 162, such as the second laminate layer 162 b canadditionally or alternatively include non-polymer materials. Forinstance, a thermoplastic fluoropolymer material can be reinforced withglass fibers or carbon fibers. The second laminate layer 162 b caninclude fiberglass reinforced plastic, and/or woven fiberglass. Suchreinforced materials can be advantageous for use in high-traffic areas.

As shown in FIG. 3A, the second laminate layer 162 b has a first side170 a and a second side 170 b. The second laminate layer 162 b has anopaque appearance 172 or unclear appearance, in that it will nottransmit light through it.

The decorative laminate 110 further comprises a decorative layer 176disposed selectively between the first laminate layer 162 a and thesecond laminate layer 162 b. It will be understood by those having skillin the art that when a layer is described as being “disposed selectivelybetween” layers or “disposed on” another layer, it may be formeddirectly on the layer or one or more intervening layers may be providedtherebetween.

In the present example, the decorative layer 176 comprises a decorativeink layer. The decorative layer 176 can comprise one or more of an inkjet printed ink, a silk screen printed ink, a pigment-based ink, adye-based ink, a paint, a stain, a digital printed ink, or anothersuitable material.

The decorative layer 176 includes a first side 178 a and a second side178 b. The first side 178 a of the decorative layer 176 is adjacent thesecond side 164 b of the first laminate layer 162 a, and the second side178 b of the decorative layer 176 is adjacent the first side 170 a ofthe second laminate layer 162 b. The decorative layer 176 can have athickness in a range of from about 0.25 mil to about 5.0 mils, althoughother suitable thicknesses can be used.

The decorative layer 176 can be deposited or applied between the firstlaminate layer 162 a and the second laminate layer 162 b. The decorativelayer 176 can be printed on the second side 164 b of the first laminatelayer 162 a to form a printed decorative material side 166. Thedecorative layer 176 can be deposited between the first laminate layer162 a and the second laminate layer 162 b or printed onto the firstlaminate layer 162 a via a printing process. The printing process cancomprise an ink jet printing process, a silkscreen printing process, adigital printing process, or another suitable printing process.

The decorative laminate 110 further comprises a resin layer 184 disposedon the second laminate layer 162 b. As shown in FIG. 3A, the resin layer184 has a first side 188 a and a second side 188 b. The first side 188 aof the resin layer 184 is adjacent the second side 170 b of the secondlaminate layer 162 b. The resin layer 184 can have a thickness in arange of from about 0.25 mil to about 5.0 mils, although other suitablethicknesses can be used.

The resin layer 184 can be disposed between the decorative layer 176 andthe second laminate layer 162 b. That is, the first side 188 a of theresin layer 184 can be adjacent the second side 178 b of the decorativelayer 176 and the second side of the resin layer 184 can be adjacent thefirst side 170 a of the second laminate layer 162 b. Such a sequence oflayers can be used with a second laminate layer 162 b that comprisesfiberglass, as described above.

The resin layer 184 can comprise an emboss resin layer, a prepreg resinlayer, or another suitable resin material layer. The resin material ofthe resin layer 184 can be a texture retention material that forms to anintroduced texture when processed, and that maintains that texture aftercuring. The emboss resin layer 184 can comprise one or more thermosetresin materials 186 consisting of epoxies, polyesters, phenols,polyurethanes, and/or a combination thereof. The thermoset resinmaterial 186 can provide texture support, retention, and adhesion forthe laminate layer(s) 162 adjacent the thermoset resin material 186 ofthe resin layer 184, and in particular, for polyvinyl fluoride (PVF)films. The emboss resin layer 184 can be a pigmented embossable resin,such as the thermoset resin material 186, which can be embossed toprovide texture to the decorative laminate 110, and which can be coloredto match the color or the predominant color of the image or designprinted upon the first laminate layer 162 a or another laminate layer162.

The decorative laminate 110 can further comprise an optional adhesivelayer 190 disposed between the decorative laminate 110 and a bondingsurface 196 of the structural component 128, such as in the form ofinterior structural component 128 a. As shown in FIG. 3A, the adhesivelayer 190 comprises a first side 192 a and a second side 192 b. Thefirst side 192 a of the adhesive layer 190 is adjacent the second side188 b of the resin layer 184, and the second side 192 b of the adhesivelayer 190 is adjacent the bonding surface 196. The adhesive layer 190can have a thickness in a range of from about 0.25 mil to about 5.0mils, although other suitable thicknesses can be used.

The adhesive layer 190 can comprise a pressure sensitive adhesive 190 athat can be applied or integrated with the decorative laminate 110. Thepressure sensitive adhesive 190 a can have a release liner 194 that maybe removed and discarded when the decorative laminate 110 is applied tothe structural component 128.

The adhesive layer 190 can comprise a spray glue, or other suitablespray or liquid adhesive material. The spray glue can be applied to thebonding surface 196 of the structural component 128, when the decorativelaminate 110 is applied to the structural component 128.

The first laminate layer 162 a, the decorative layer 176, and the secondlaminate layer 162 b together comprise a top portion 198 a or a topsheet. The top portion 198 a, together with the resin layer 184, canform a decorative laminate 110 that is flexible and that can be easilyformed around corners, contours, or curved portions of a structure, suchas a structural component 128.

The first laminate layer 162 a, the decorative layer 176, the secondlaminate layer 162 b, and the resin layer 184 are sequentially layeredand laminated together to form the decorative laminate 110 and areconfigured for application to the structural component 128. Thestructural component 128, such as interior structural component 128 a,has the bonding surface 196.

When decorative laminate 110 is applied to structural component 128,first laminate layer 162 a can be outermost. That is, people orsubstances that contact decorative laminate 110 can contact firstsurface 164 a of first laminate layer 162 a. Microorganisms transferredto the laminate may be killed, or their growth inhibited by the silverparticles 181, or other anti-microbial agent, of first laminate layer162 a.

B. Illustrative Anti-Microbial Decorative Laminate

As shown in FIGS. 4A-4B, this section describes an illustrativedecorative laminate 210. Decorative laminate 210 is another example ofanti-microbial decorative laminate 10, as described above. FIG. 4A is anexploded side view of decorative laminate 210, and FIG. 4B is anassembled side view of the decorative laminate. As shown, decorativelaminate 210 includes a top portion 298 a comprised of a first laminatelayer 262 a, a decorative layer 276, and a second laminate layer 262 b.The decorative laminate 210 also includes a base portion 298 b, or baselayer, comprised of a third laminate layer 262 c, and a resin layer 284disposed between the second laminate layer 262 b and the third laminatelayer 262 c. The presence of the base portion 298 b can create a morerigid decorative laminate 210 that is beneficial for application to flator substantially flat surfaces.

The first laminate layer 262 a, the decorative layer 276, the secondlaminate layer 262 b, the resin layer 284, and the third laminate layer262 c, are sequentially layered and laminated together to form thedecorative laminate 210, and are configured for application to astructural component 228. The structural component 228 has a bondingsurface 296.

As shown in FIG. 4A, the first laminate layer 262 a has a first side 264a, a second side 264 b, and a transparent appearance 268, or clearappearance, in that it will transmit light through it. The secondlaminate layer 262 b has a first side 270 a and a second side 270 b.

As shown in FIG. 4A, the third laminate layer 262 c comprises a firstside 275 a and a second side 275 b. The first side 275 a of the thirdlaminate layer 262 c is adjacent the second side 288 b of the resinlayer 284, and the second side 275 b of the third laminate layer 262 cis adjacent the first side 292 a of the adhesive layer 290, when theadhesive layer 290 is included. The third laminate layer 262 c, as wellas the second laminate layer 262 b may each have an opaque appearance272 or unclear appearance, in that they will not transmit light throughthem.

In the present example, the first laminate layer 262 a is comprised of atransparent a thermoplastic fluoropolymer material 274 such as apolyvinyl fluoride (PVF) film, with an anti-microbial coating 281disposed on the thermoplastic fluoropolymer material 274. Theanti-microbial coating 281 therefore comprises the first side 264 a ofthe first laminate layer 262 a. The anti-microbial coating 281 caninclude a phenolic compound such as para-tert-amylphenol (PTAP) and/or asolution thereof. The anti-microbial coating can also be transparent,and sufficiently heat and pressure resistant as to tolerate laminationwithout adverse effect.

The second laminate layer 262 b and the third laminate layer 262 c caneach be comprised of a thermoplastic fluoropolymer material 274. Asdiscussed above, the thermoplastic fluoropolymer material 274 caninclude a polyvinyl fluoride (PVF) film, a polyvinylidene fluoride(PVDF) film, an integral color polyvinyl fluoride (PVF) film, apolyvinyl fluoride (PVF) film/aluminum foil/adhesive material, oranother suitable thermoplastic fluoropolymer material.

The decorative laminate 210 further comprises the decorative layer 276disposed selectively between the first laminate layer 262 a and thesecond laminate layer 262 b. The decorative layer 276 comprises a firstside 278 a and a second side 278 b, with the first side 278 a of thedecorative layer 276 adjacent the second side 264 b of the firstlaminate layer 262 a, and the second side 278 b of the decorative layer276 adjacent the first side 270 a of the second laminate layer 262 b.

The decorative layer 276 comprises one or more opaque or visiblematerials, disposed selectively between the first laminate layer 262 aand the second laminate layer 262 b. The decorative layer 276 cancomprise one or more of an ink jet printed ink, a silk screen printedink, a pigment-based ink, a dye-based ink, a paint, a stain, a digitalprinted ink, or another suitable material.

The decorative layer 276 can be deposited or applied between the firstlaminate layer 262 a and the second laminate layer 262 b. The decorativelayer 276 can be printed on the second side 264 b of the first laminatelayer 262 a to form the printed decorative material side 266. Thedecorative layer 276 can be deposited between the first laminate layer262 a and the second laminate layer 262 b or printed onto the firstlaminate layer 262 a via a printing process, as discussed above fordecorative laminate 110.

The decorative laminate 210 further comprises a resin layer 284 disposedon the second laminate layer 262 b. As further shown in FIG. 4A, theresin layer 284 has a first side 288 a and a second side 288 b. Thefirst side 288 a of the resin layer 284 is adjacent the second side 270b of the second laminate layer 262 b, and the second side 288 b of theresin layer 284 is adjacent the first side 275 a of the third laminatelayer 262 c.

The resin layer 284 can comprise an emboss resin layer, a prepreg resinlayer, or another suitable resin material layer. The emboss resin layer284 can comprise one or more thermoset resin materials 286, as discussedfor decorative laminate 110 above.

The decorative laminate 210 can further comprise an optional adhesivelayer 290 disposed between the third laminate layer 262 c and thebonding surface 296 of the structural component 228. As shown in FIG.4A, the adhesive layer 290 has a first side 292 a and a second side 292b. The first side 292 a of the adhesive layer 290 is adjacent the secondside 275 b of the third laminate layer 262 c, and the second side 292 bof the adhesive layer 290 is adjacent the bonding surface 296. In thepresent example, the adhesive layer 290 comprises a spray glue layer 290b. However, other suitable spray or liquid adhesive materials may beused. Alternatively, the adhesive layer 290 can comprise a pressuresensitive adhesive 290 a that may be applied or integrated with thedecorative laminate 210.

C. Illustrative Anti-Microbial Decorative Laminate with Light ActivatedMaterials

As shown in FIGS. 5A-5B, this section describes an illustrativedecorative laminate 310. Decorative laminate 310 is another example ofanti-microbial decorative laminate 10, as described above. FIG. 5A is anexploded side view of decorative laminate 310, and FIG. 5B is anassembled side view of the decorative laminate. As shown, decorativelaminate 310 includes a first laminate layer 362 a, a decorative layer376, a second laminate layer 362 b, a third laminate layer 362 c, and aresin layer 384.

The first laminate layer 362 a, the decorative layer 376, the secondlaminate layer 362 b, the third laminate layer 362 c, and the resinlayer 384 are sequentially layered and laminated together to form thedecorative laminate 310, which is configured for application to astructural component 328. The structural component 328 has a bondingsurface 396.

In this example, as shown in FIGS. 5A-5B, the third laminate layer 362 cand the resin layer 384 of the decorative laminate 310 c are in areverse order, as compared to the decorative laminate 210 of FIGS.4A-4B. As shown in FIGS. 5A-5B, the decorative laminate 310 includes atop portion 398 a, or top sheet, comprised of the first laminate layer362 a, the decorative layer 376, and the second laminate layer 362 b,and includes a base portion 398 b, or base layer, comprised of the thirdlaminate layer 362 c and the resin layer 384.

As further shown in FIGS. 5A-5B, the decorative laminate 310 has thethird laminate layer 362 c disposed between the second laminate layer362 b and the resin layer 384. Again, as with the decorative laminate210 in FIGS. 4A-4B, the presence of the base portion 398 b can create amore rigid decorative laminate 310 that is beneficial for application toflat or substantially flat surfaces.

As shown in FIG. 5A, the second laminate layer 362 b has a first side370 a and a second side 370 b. The third laminate layer 362 c includes afirst side 375 a and a second side 375 b. The first side 375 a of thethird laminate layer 362 c is adjacent the second side 370 b of thesecond laminate layer 362 b, and the second side 375 b of the thirdlaminate layer 362 c is adjacent the first side 388 a of the resin layer384.

The third laminate layer 362 c, as well as the second laminate layer 362b can each have the opaque appearance 372 or unclear appearance, in thatthey will not transmit light through them. Similarly to the decorativelaminate 210 of FIGS. 4A-4B discussed above, the second laminate layer362 b and the third laminate layer 362 c can each be comprised of athermoplastic fluoropolymer material 374.

The second laminate layer 362 b or the third laminate layer 362 c caninclude a foil, such as aluminum foil, adhered to the thermoplasticfluoropolymer material. For instance, the second laminate layer 362 bcan include a layer of foil that is bonded to a thermoplasticfluoropolymer film, and forms the second side 370 b of the secondlaminate layer 362 b. The foil can therefore contact the first side 375a of the third laminate layer 362 c.

As further shown in FIG. 5A, the first laminate layer 362 a has a firstside 364 a, a second side 364 b, and a transparent appearance, or clearappearance, in that it will transmit light through it. In the presentexample, the first laminate layer 362 a is comprised of a transparent athermoplastic fluoropolymer material 374 such as a polyvinyl fluoride(PVF) film, with an anti-microbial coating 381 on the first side 364 a.The anti-microbial coating 381 can include a finely powdered metal suchas silver, zinc, or copper mixed with a transparent or non-visible inkmaterial. The ink material and powdered metal can be printed on thefirst side 364 a of the first laminate layer 362 a to form a printedanti-microbial side. The ink material and powdered metal can be printeduniformly over first side 364 a and/or can be printed in a pattern suchas a grid. The printing process can comprise an ink jet printingprocess, a silkscreen printing process, a digital printing process, oranother suitable printing process.

The decorative laminate 310 further comprises the decorative layer 376disposed selectively between the first laminate layer 362 a and thesecond laminate layer 362 b. As shown in FIGS. 5A-5B, the decorativelayer 376 includes a first side 378 a and a second side 378 b, with thefirst side 378 a of the decorative layer 376 adjacent the second side364 b of the first laminate layer 362 a, and the second side 378 b ofthe decorative layer 376 adjacent the first side 370 a of the secondlaminate layer 362 b.

The decorative layer 376 comprises one or more visible materials 380disposed selectively between the first laminate layer 362 a and thesecond laminate layer 362 b. The one or more visible materials 380 cancomprise one or more of a visible ink jet printed ink, a visible silkscreen printed ink, a visible pigment-based ink, a visible dye-basedink, a visible paint, a visible stain, a visible digital printed ink, oranother suitable visible material.

The decorative layer further comprises one or more non-visible lightactivated materials 382 disposed selectively between the first laminatelayer 362 a and the second laminate layer 362 b. The one or morenon-visible light activated materials 382 can change from a non-visiblestate to a visible state when exposed to a light source 412. The lightsource 412 can be an ultraviolet (UV) light source, an infrared (IR)light source, a light-emitting diode (LED) light source, or anothersuitable light source.

The one or more non-visible light activated materials 382 can compriseone or more of a non-visible ink jet printed ink, a non-visible silkscreen printed ink, a non-visible pigment-based ink, a non-visiblepaint, a non-visible stain, a non-visible digital printed ink, oranother suitable non-visible light activated material, each configuredto change from the non-visible state to the visible state, when exposedto the light source 412. For example, the non-visible light activatedmaterials 382 can comprise light activated or light sensitive materials,such as ultraviolet light sensitive non-visible or invisible inks.Ultraviolet light sensitive non-visible or invisible inks are a class ofinks which are non-visible or invisible to the naked eye, but becomehighly visible under ultraviolet light.

The decorative layer 376 may be deposited or applied between the firstlaminate layer 362 a and the second laminate layer 362 b. The decorativelayer 376 can be printed on the second side 164 b of the first laminatelayer 162 a to form a printed decorative material side 366. Thedecorative layer 376 can be deposited between the first laminate layer362 a and the second laminate layer 362 b or printed onto the firstlaminate layer 362 a via a printing process. The printing process cancomprise an ink jet printing process, a silkscreen printing process, adigital printing process, or another suitable printing process.

The decorative laminate 310 further comprises the resin layer 384disposed on the third laminate layer 362 c. As further shown in FIG. 5A,the resin layer 384 has a first side 388 a and a second side 388 b. Thefirst side 388 a of the resin layer 384 is adjacent the second side 375b of the third laminate layer 362 c, and the second side 388 b of theresin layer 384 is adjacent the first side 392 a of the adhesive layer390. The resin layer 384 comprises a prepreg resin layer.

The decorative laminate 310 can further comprise the optional adhesivelayer 390 disposed between resin layer 384 and the bonding surface 396of the structural component 328. As shown in FIG. 5A, the adhesive layer390 includes a first side 392 a and a second side 392 b. The first side392 a of the adhesive layer 390 is adjacent the second side 388 b of theresin layer 384, and the second side 392 b of the adhesive layer 390 isadjacent the bonding surface 396. In the present example, the adhesivelayer 390 comprises a spray glue layer. However, other suitable spray orliquid adhesive materials can be used. Alternatively, the adhesive layer390 can comprise a pressure sensitive adhesive 390 a that can be appliedor integrated with the decorative laminate 310.

D. Anti-microbial Structural Components and Composite Panels

FIG. 6 is an illustration of a front perspective view of assembledstructural composite panels 328 b, such as cured structural compositepanels, each with anti-microbial decorative laminate 310 as describedabove, having a positional system pattern 400. Each decorative laminate310 has a top portion 398 a and a base portion 398 b.

Each decorative laminate 310 include the visible material 380, e.g., inthe form of arrow images, and comprises the non-visible light activatedmaterial 382 in the form of the positional system pattern 400. Thenon-visible light activated material 382 forms the positional systempattern 400 such as an alignment pattern 400 a on a decorative area 404of each decorative laminate 310. The non-visible light activatedmaterial 382 can be deposited or printed on the decorative laminate 310in the alignment pattern 400 a to facilitate alignment and positioningof the decorative laminate 310, when applied to a structural component328. Furthermore, each decorative laminate 310 includes anti-microbialagent in anti-microbial coating 381, as described previously.

Non-decorative information or markings, such as manufacturing positionaltargets 402 a, 402 b, comprised of non-visible light activated material382 can be included on the positional system pattern of each decorativelaminate 310. When illuminated with a light source, such as anultraviolet (UV) light source, an infrared (IR) light source, or anothersuitable light source, the manufacturing positional targets 402 a, 402 bcan provide manufacturers, manufacturing-related users, or other users,with visible target reference points for positioning and aligning thedecorative laminate 310 on the structural composite panel 328 b. Inaddition, the manufacturing positional targets 402 a, 402 b remainintact and do not get trimmed off of the final manufactured version ofthe decorative laminate 310 applied on a structural composite panel 328b.

Non-decorative information or markings, such as assembly positionaltargets 402 c, comprised of non-visible light activated material 382 canbe included on the positional system pattern of each decorative laminate310. The assembly positional targets 402 c along an alignment seam 406are formed between the two decorative laminates 310 of the tworespective structural composite panels 328 b to facilitate alignment andpositioning of the decorative laminates 310 and the structural compositepanels 328 b with one another.

When illuminated with the light source, such as an ultraviolet (UV)light source, an infrared (IR) light source, or another suitable lightsource, the assembly positional targets 402 c can provide assemblers,assembly-related users, or other users, with visible target referencepoints for aligning the decorative laminates 310 on each structuralcomposite panel 328 b with one another. In addition, the assemblypositional targets 402 c remain intact and do not get trimmed off of thefinal manufactured or assembled version of the decorative laminate 310applied on the structural composite panels 328 b.

In addition to the manufacturing positional targets 402 a, 402 b and theassembly positional targets 402 c, the non-visible light activatedmaterial 382 can be deposited or printed on the decorative laminate 310in the form of other non-decorative information or markings, such aspart numbers, bar codes, repair instructions, or other non-decorativeinformation, to locate and identify structural components forinspection, repair, removal, maintenance, or other procedure.

Referring now to FIGS. 7A-7B, FIG. 7A shows a front perspective view ofa structural component 328 with decorative laminate 310 showing a firsttheme 408, e.g., the number “777”, such as an image or design, that isvisible and showing a second theme 410, e.g., sun and cloud, such as animage or design, that is non-visible. FIG. 7B is an illustration of afront perspective view of the structural component 328 of FIG. 7A, withdecorative laminate 310 showing the first theme 408, e.g., the number“777”, that is visible, and showing the second theme 410, e.g., sun andcloud, that is visible when exposed to and illuminated by a lightingsource 412.

Decorative laminate 310 has a top portion 398 a, a base portion 398 b,and a decorative area 404. The visible material 380 forms the firsttheme 408, e.g., the number “777”, and the non-visible light activatedmaterial 382 forms the second theme 410, e.g., sun and cloud. The secondtheme 410 can be separate and distinct from the first theme 408.Alternatively, the second theme 410 can augment the first theme 408,that is, the second theme 410 can be part of, connected to, or highlightthe first theme 408 in some manner. The top portion of laminate 310 caninclude anti-microbial coating 381 as described above, and/or anyanti-microbial agent, for example dispersed in the top portion orapplied as a layer.

In FIG. 7A, the first theme 408 comprised of visible material 380 isvisible, and the second theme 410 comprised of non-visible lightactivated material 382 is non-visible and in a non-visible state orcondition. In FIG. 7B, the first theme 408 comprised of visible material380 is visible, and the second theme 410 comprised of non-visible lightactivated material 382 is now visible via illumination 414 from andexposure to the light source 412, such as in the form of ultraviolet(UV) light source 412 a. In FIG. 7B, the second theme 410 has changedfrom the non-visible state to the visible state (FIG. 9B) with exposureto the light source 412.

As further shown in FIG. 7B, a lighting system 418 such as an aircraftlighting system, is coupled to or connected to the light source 412 viaa connection element 416, such as a wired or wireless connection. Thelight source 412, such as ultraviolet (UV) light source 412 a isconfigured to illuminate and change the non-visible light activatedmaterial 382 from the non-visible state to the visible state. The lightsource 412 can also comprise an infrared (IR) light source, alight-emitting diode (LED) light source, or another suitable lightsource.

E. Illustrative Method of Making Anti-Microbial Decorative Laminate

This section describes steps of an illustrative method for makinganti-microbial decorative laminate; see FIG. 8. Aspects of decorativelaminates, laminate layers, and/or decorative layers described above canbe utilized in the method steps described below. Where appropriate,reference may be made to components and systems that may be used incarrying out each step. These references are for illustration, and arenot intended to limit the possible ways of carrying out any particularstep of the method.

FIG. 8 is a flowchart illustrating steps performed in an illustrativemethod. Although various steps of method 500 are described below anddepicted in FIG. 8, the steps need not necessarily all be performed, andin some cases may be performed simultaneously, or in a different orderthan the order shown. Based on the present disclosure, it should beunderstood that additional steps may be performed, without departingfrom the present claims.

At step 502, the method includes depositing a decorative layer between afirst laminate layer and a second laminate layer. The first and secondlaminate layers can each include a thermoplastic fluoropolymer material.The first laminate layer can be clear or transparent, and can furtherinclude an anti-microbial agent.

Incorporating the anti-microbial agent in the first laminate layer priorto manufacture of the decorative laminate can simplify production of thedecorative laminate, allowing use of well-tested procedures and existingequipment. Alternatively, the anti-microbial agent can be incorporatedinto the first laminate layer after manufacture of the decorativelaminate. This order of method steps may be appropriate to temperatureor pressure-sensitive anti-microbial agents that might undergo unwantedchemical or physical changes during lamination.

The anti-microbial agent can include any effective chemical agents,biological agents, and/or any combination of agents, including but notlimited to bacteriostatic agents, fungistatic agents, antibiotic agents,and fungicides. For example, the anti-microbial agent can be a metalsuch as silver, copper, zirconium, sodium, potassium, and/or anycombination thereof. For another example, the anti-microbial agent canbe a phenolic such as para-tert-amylphenol (PTAP).

The anti-microbial agent and thermoplastic fluoropolymer material of thefirst laminate layer can be incorporated, adhered, aggregated, orotherwise combined in any effective manner. The anti-microbial agent canbe homogenously distributed throughout the thermoplastic fluoropolymermaterial, can be localized proximate one side of the first laminatelayer, and/or can be disposed according to some pattern. Theanti-microbial agent and the polymer material can be combined in such amanner as to achieve a desired transparency of first laminate layer.

The decorative layer can include one or more visible materials. Thedecorative layer can further include one or more non-visible lightactivated materials that change from a non-visible state to a visiblestate when exposed to a light source. The light source can be anultraviolet (UV) light source, an infrared (IR) light source, or anothersuitable light source.

Step 502 can include depositing the decorative layer via a printingprocess. The printing process can include an ink jet printing process, asilkscreen printing process, a digital printing process, or anothersuitable printing process. Step 502 can further include depositing oneor more of the non-visible light activated materials in an alignmentpattern to facilitate alignment of the completed laminate, when appliedto a cured structural composite panel.

The method 500 then includes step 504 of applying a resin layer to thesecond laminate layer. The method 500 further includes step 506 offorming a decorative laminate by layering sequentially and laminatingtogether at a specified heat and a specified pressure the first laminatelayer, the decorative layer, the second laminate layer, and the resinlayer.

Step 506 can include using a press forming process to heat and cure thefirst laminate layer, the decorative layer, the second laminate layer,and the resin layer at a specified heat, such as an effective elevatedtemperature, and at a specified pressure, such as an effective pressure,for an effective period of time to form the decorative laminate. Thefirst laminate layer, the decorative layer, the second laminate layer,and the resin layer can be layered and laid up on a flat configuration,such as a flat metal caul plate or the like, in large sheets, e.g., 5feet by 8 feet. The large sheets can be heated and cured in a multipleopening press, such as with flat platens, used in the press formingprocess.

The effective elevated temperature for heating and curing the decorativelaminate can be in a range of from about 200 F (two hundred degreesFahrenheit) to about 400 F (four hundred degrees Fahrenheit), or more.The effective period of time for heating and curing the decorativelaminate can be in a range of from about 10 (ten) minutes to about 120(one hundred twenty) minutes, or more. The effective pressure forheating and curing the decorative laminate can be at a pressure, forexample, in a range of from about 150 psi (fifty pounds per square inch)to about 200 psi (two hundred pounds per square inch). The temperature,pressure, and time selected for the heating and curing can be selectedbased on the type of resin layer used in the forming the decorativelaminate, for example, a thermoset resin or a thermoplastic resin, orthe type of thermoset resin or type of thermoplastic resin used.

The large sheets of the laid up first laminate layer, decorative layer,second laminate layer, and resin layer can be heated and cured in amultiple opening press at a pressure in a range of from about 150 psi(fifty pounds per square inch) to about 200 psi (two hundred pounds persquare inch), at a temperature in a range of from about 200 F (twohundred degrees Fahrenheit) to about 400 F (four hundred degreesFahrenheit), and at a time in a range of from about 10 (ten) minutes toabout 120 (one hundred twenty) minutes. For example, the thermal cyclecan have a duration of approximately 60 (sixty) minutes including rampup and ramp down times, and can maintain a maximum temperature for asmuch as 20 (twenty) minutes. The decorative laminate can be cooled inthe multiple opening press to ambient temperature for a sufficient timeperiod and then removed for application to a structural component, suchas an aircraft interior structural component. The decorative laminatecan also be formed with other known press forming processes.

Step 508 of the method includes curing a structural composite panel.Step 510 includes applying the decorative laminate to a bonding surfaceof the cured structural composite panel with an adhesive layer. Theadhesive layer can comprise a pressure sensitive adhesive with a releaseliner, a spray glue, or another suitable adhesive material. The curedstructural composite panel may form part of structural component. Thestructural component may be an interior structural component of anaircraft, rotorcraft, spacecraft, watercraft, automobile, truck, and/orother vehicle. Step 510 can further include applying the decorativelaminate to one or more of a flat surface, a curved surface, a contouredsurface, or another suitable surface, of the structural component.

Method 500 further includes the optional step 512 of adding anadditional laminate layer adjacent either a first side or a second sideof the resin layer. Step 512 can be repeated as appropriate, to add oneor more additional laminate layers. Additionally, optional flameretardant material or other laminate materials can be added to thedecorative laminate. Further, the decorative laminate can be applied tothe structural component 128 using known processes such asthermoforming, vacuum forming, or another suitable known applicationprocesses.

F. Illustrative Aircraft and Associated Method

Examples disclosed herein can be described in the context of anillustrative aircraft manufacturing and service method 600 (see FIG. 9)and an illustrative aircraft 620 (see FIG. 10). Method 600 includes aplurality of processes, stages, or phases. During pre-production, method600 can include a specification and design phase 604 of aircraft 620 anda material procurement phase 606. During production, a component andsubassembly manufacturing phase 608 and a system integration phase 610of aircraft 620 can take place. Thereafter, aircraft 620 can go througha certification and delivery phase 612 to be placed into in-servicephase 614. While in service (e.g., by an operator), aircraft 620 can bescheduled for routine maintenance and service 616 (which may alsoinclude modification, reconfiguration, refurbishment, and so on of oneor more systems of aircraft 620). While the examples described hereinrelate generally to production during component and subassemblymanufacturing phase 608 of aircraft 620, they can be practiced at otherstages of method 600.

Each of the processes of method 600 can be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator can include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party can include, withoutlimitation, any number of vendors, subcontractors, and suppliers; and anoperator can be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 10, aircraft 620 produced by illustrative method 600can include a frame 622 with a plurality of systems 624 and an interior626. Although an aerospace example is shown, the principles disclosedherein can be applied to other industries, such as the automotiveindustry, rail transport industry, and nautical engineering industry.

Accordingly, in addition to aircraft 620, the principles disclosedherein can apply to other vehicles, e.g., land vehicles, marinevehicles, etc. In any of these cases, interior 626 can includedecorative laminates that incorporate anti-microbial agents according tothe teachings of the present disclosure.

Apparatuses and methods shown or described herein can be employed duringany one or more of the stages of the manufacturing and service method600. For example, components or subassemblies corresponding to componentand subassembly manufacturing phase 608 can be fabricated ormanufactured in a manner similar to components or subassemblies producedwhile aircraft 620 is operating during in-service phase 614. Also, oneor more examples of the apparatuses, methods, or combinations thereofcan be utilized during production stages 608 and 610, for example, bysubstantially expediting assembly of or reducing the cost of aircraft620. Similarly, one or more examples of the apparatus or methodrealizations, or a combination thereof, can be utilized, for example andwithout limitation, while aircraft 620 is in production and/or duringmaintenance and service phase 616.

G. Illustrative Combinations and Additional Examples

This section describes additional aspects and features of anti-microbialdecorative laminates and related systems and methods, presented withoutlimitation as a series of paragraphs, some or all of which may bealphanumerically designated for clarity and efficiency. Each of theseparagraphs can be combined with one or more other paragraphs, and/orwith disclosure from elsewhere in this application, including thematerials incorporated by reference, in any suitable manner. Some of theparagraphs below expressly refer to and further limit other paragraphs,providing without limitation examples of some of the suitablecombinations.

A0. A decorative laminate comprising:

a first laminate layer containing an anti-microbial agent;

a second laminate layer;

a decorative layer disposed selectively between the first laminate layerand the second laminate layer, the decorative layer comprising:

one or more visible materials; and one or more non-visible lightactivated materials that change from a non-visible state to a visiblestate, when exposed to a light source, the light source comprising anultraviolet (UV) light source or an infrared (IR) light source; and

a resin layer disposed on the second laminate layer,

wherein the first laminate layer and the second laminate layer eachcomprise a thermoplastic fluoropolymer material, and

wherein the first laminate layer, the decorative layer, the secondlaminate layer, and the resin layer are laminated together to form thedecorative laminate configured for application to a structuralcomponent.

A1. The decorative laminate of A0, further comprising an adhesive layerdisposed between the decorative laminate and a bonding surface of thestructural component.

A2. The decorative laminate of any of A0-A1, further comprising one ormore additional laminate layers adjacent a first side of the resinlayer.

A3. The decorative laminate of any of A0-A2, further comprising one ormore additional laminate layers adjacent a second side of the resinlayer.

A4. The decorative laminate of any of A0-A3, wherein the one or morenon-visible light activated materials are deposited in an alignmentpattern that facilitate alignment of the decorative laminate whenapplied to the structural component.

A5. The decorative laminate of any of A0-A4, wherein the one or morevisible materials comprise one or more of a visible ink jet printed ink,a visible silk screen printed ink, a visible pigment-based ink, avisible dye-based ink, a visible paint, a visible stain, and a visibledigital printed ink.

A6. The decorative laminate of any of A0-A5, wherein the one or morenon-visible light activated materials comprise one or more of anon-visible ink jet printed ink, a non-visible silk screen printed ink,a non-visible pigment-based ink, a non-visible dye-based ink, anon-visible paint, a non-visible stain, and a non-visible digitalprinted ink, each configured to change from the non-visible state to thevisible state when exposed to the light source.

A7. The decorative laminate of any of A0-A6, wherein the anti-microbialagent is finely powdered silver dispersed within the first laminatelayer.

A8. The decorative laminate of any of A0-A7, wherein the anti-microbialagent is selected from the group consisting of silver, copper,zirconium, sodium, potassium and para-tert-amylphenol (PTAP).

A9. The decorative laminate of any of A0-A8, wherein the resin layercomprises an emboss resin layer or a prepreg resin layer, the embossresin layer comprising one or more thermoset resin materials selectedfrom the group consisting of epoxies, polyesters, phenols,polyurethanes, and a combination thereof.

A10. The decorative laminate of any of A0-A9, wherein the structuralcomponent comprises an interior structural component, a structuralcomposite panel, an aircraft interior structural component, a rotorcraftinterior structural component, a spacecraft interior structuralcomponent, a watercraft interior structural component, an automobileinterior structural component, or a truck interior structural component.

B0. A decorative laminate system comprising:

a structural component having a bonding surface;

a decorative laminate applied to the bonding surface of the structuralcomponent, the decorative laminate comprising:

a first laminate layer having a transparent appearance and containing ananti-microbial agent;

a second laminate layer having an opaque appearance, the first laminatelayer and the second laminate layer each comprising a thermoplasticfluoropolymer material selected from the group consisting of polyvinylfluoride (PVF) film, polyvinylidene fluoride (PVDF) film, integral colorpolyvinyl fluoride (PVF) film, and polyvinyl fluoride (PVF)film/aluminum foil/adhesive material;

a decorative layer disposed between the first laminate layer and thesecond laminate layer, the decorative layer comprising:

-   -   one or more visible materials; and    -   one or more non-visible light activated materials;

a resin layer disposed on the second laminate layer;

an adhesive layer disposed between the decorative laminate and thebonding surface of the structural component; and

a lighting system having a light source configured to illuminate andchange the one or more non-visible light activated materials from anon-visible state to a visible state, the light source comprising anultraviolet (UV) light source or an infrared (IR) light source.

B1. The decorative laminate system of B0, wherein the decorativelaminate further comprises one or more additional laminate layersadjacent either a first side of the resin layer, or a second side of theresin layer.

B2. The decorative laminate system of any of B0-B1, wherein the one ormore visible materials comprise one or more of a visible ink jet printedink, a visible silk screen printed ink, a visible pigment-based ink, avisible dye-based ink, a visible paint, a visible stain, and a visibledigital printed ink,

B3. The decorative laminate system of any of B0-B2, wherein the one ormore non-visible light activated materials comprise one or more of anon-visible ink jet printed ink, a non-visible silk screen printed ink,a non-visible pigment-based ink, a non-visible dye-based ink, anon-visible paint, a non-visible stain, and a non-visible digitalprinted ink, each configured to change from the non-visible state to thevisible state when exposed to the light source.

B4. The decorative laminate system of any of B0-B3, wherein theanti-microbial agent is either a finely powdered metal selected from thegroup consisting of silver, copper, zirconium, sodium and potassium, ora phenolic,

C0. A method of making a composite panel having a decorative laminateapplied thereto, the method comprising the steps of:

depositing a decorative layer between a first laminate layer and asecond laminate layer, wherein the first laminate layer and the secondlaminate layer each comprise a thermoplastic fluoropolymer material andwherein the first laminate layer further comprises an anti-microbialagent, the decorative layer comprising:

-   -   one or more visible materials; and    -   one or more non-visible light activated materials that change        from a non-visible state to a visible state, when exposed to a        light source, the light source comprising an ultraviolet (UV)        light source or an infrared (IR) light source;

applying a resin layer to the second laminate layer;

forming a decorative laminate by layering sequentially and laminatingtogether at a specified heat and a specified pressure the first laminatelayer, the decorative layer, the second laminate layer, and the resinlayer;

curing a structural composite panel to form a cured structural compositepanel; and

applying with an adhesive layer the decorative laminate to a bondingsurface of the cured structural composite panel to form the compositepanel having the decorative laminate applied thereto.

C1. The method of C0, wherein the anti-microbial agent is either apowdered metal or a phenolic.

C2. The method of any of C0-C1, wherein the step of depositing thedecorative layer between the first laminate layer and the secondlaminate layer further comprises depositing the decorative layer via anink jet printing process, a silkscreen printing process, or a digitalprinting process.

C3. The method of any of C0-C2, wherein the step of depositing thedecorative layer between the first laminate layer and the secondlaminate layer further comprises depositing the one or more of thenon-visible light activated materials in an alignment pattern tofacilitate alignment of the decorative laminate, when applied to thecured structural composite panel.

D0. A decorative laminate comprising:

a first laminate layer containing an anti-microbial agent;

a second laminate layer; and

a decorative layer disposed selectively between the first laminate layerand the second laminate layer;

wherein the first laminate layer and the second laminate layer eachcomprise a thermoplastic fluoropolymer material, and

wherein the first laminate layer, the decorative layer, and the secondlaminate layer are laminated together to form the decorative laminateconfigured for application to a structural component.

D1. The decorative laminate of D0, further comprising an adhesive layerdisposed between the decorative laminate and a bonding surface of thestructural component.

D2. The decorative laminate of any of D0-D1, further comprising one ormore additional laminate layers adjacent a first side of the decorativelaminate layer.

D3. The decorative laminate of any of D0-D2, further comprising one ormore additional laminate layers adjacent a second side of the decorativelaminate layer.

D4. The decorative laminate of any of D0-D3, wherein the decorativelaminate layer includes one or more materials deposited in an alignmentpattern that facilitates alignment of the decorative laminate whenapplied to the structural component.

D5. The decorative laminate of any of D0-D4, wherein the decorativelaminate includes one or more of an ink jet printed ink, a silk screenprinted ink, a pigment-based ink, a dye-based ink, a paint, a stain, anda digital printed ink,

D6. The decorative laminate of any of D0-D5, wherein the anti-microbialagent is powdered silver dispersed within the first laminate layer.

D7. The decorative laminate of any of D0-D6, wherein the anti-microbialagent includes at least one of a bacteriostatic agent, a fungistaticagent, an antibiotic agent, a fungicide, or a combination thereof.

D8. The decorative laminate of any of D0-D7, wherein the decorativelayer includes a resin layer disposed on the second laminate, andwherein the resin layer includes one or more thermoset resin materials.

D9, The decorative laminate of any of D0-D8, wherein the structuralcomponent comprises a building interior structural component, a buildingstructural composite panel, an aircraft interior structural component, arotorcraft interior structural component, a spacecraft interiorstructural component, a watercraft interior structural component, anautomobile interior structural component, or a truck interior structuralcomponent.

E0. A decorative laminate system comprising:

a structural component having a bonding surface;

a decorative laminate applied to the bonding surface of the structuralcomponent, the decorative laminate comprising;

a first laminate layer having a transparent appearance and containing ananti-microbial agent;

a second laminate layer having an opaque appearance, the first laminatelayer and the second laminate layer each comprising a thermoplasticfluoropolymer material;

a decorative layer disposed between the first laminate layer and thesecond laminate layer;

a resin layer disposed on the second laminate layer; and

an adhesive layer disposed between the decorative laminate and thebonding surface of the structural component.

E1. The decorative laminate system of E0, wherein the decorativelaminate further comprises one or more additional laminate layersadjacent either a first side of the resin layer or a second side of theresin layer.

E2. The decorative laminate system of any of E0-E1, wherein thedecorative layer includes one or more of an ink jet printed ink, a silkscreen printed ink, a pigment-based ink, a dye-based ink, a paint, astain, and a digital printed ink.

E3. The decorative laminate system of any of E0-E2, wherein theanti-microbial agent is either a powdered metal or a phenolic.

E4. The decorative laminate system of any of E0-E3, wherein theanti-microbial agent includes at least one of a bacteriostatic agent, afungistatic agent, an antibiotic agent, a fungicide, or a combinationthereof.

F0. A vehicle, comprising:

a structural component; and

a decorative laminate applied to the structural component, he decorativelaminate including:

-   -   a first laminate layer containing an anti-microbial agent;    -   a second laminate layer; and    -   a decorative layer disposed selectively between the first        laminate layer and the second laminate layer;

wherein the first laminate layer and the second laminate layer eachcomprise a thermoplastic fluoropolymer material, and

wherein the first laminate layer, the decorative layer, and the secondlaminate layer are laminated together to form the decorative laminate.

F1. The vehicle of F0, wherein the anti-microbial agent is either apowdered metal or a phenolic.

F2. The vehicle of any of F0-F1, wherein the anti-microbial agentincludes a bacteriostatic agent, a fungistatic agent, an antibioticagent, a fungicide, or a combination thereof.

F3. The vehicle of any of F0-F2, further comprising a light source, andwherein the decorative layer includes one or more visible materials andone or more non-visible light activated materials that change from anon-visible state to a visible state when exposed to light emitted fromthe light source.

F4. The vehicle of any of F0-F3, wherein the decorative laminate layerincludes one or more materials deposited in an alignment pattern thatfacilitates alignment of the decorative laminate when applied to thestructural component.

G0. A method of displaying an image, comprising:

forming a decorative laminate by layering and laminating together at aspecified heat and a specified pressure:

-   -   a first laminate layer having a transparent appearance and        containing an anti-microbial agent,    -   a second laminate layer, and    -   a decorative layer including the image and disposed selectively        between the first laminate layer and the second laminate layer;

curing a structural composite panel to form a cured structural compositepanel; and

applying with an adhesive layer the decorative laminate to a bondingsurface of the cured structural composite panel.

Advantages, Features, and Benefits

The different embodiments and examples of the decorative laminatedescribed herein provide several advantages over known solutions forinhibiting microbial spread and/or growth on vehicle interior surfaces.For example, illustrative embodiments and examples described hereinprovide a permanent, durable anti-microbial material on surfacesfrequently contacted by vehicle passengers and other microorganismcarriers.

Additionally, and among other benefits, illustrative embodiments andexamples described herein allow integration of anti-microbialfunctionality into an existing component, eliminating need for aseparate installation or application process during vehicle assembly.

Additionally, and among other benefits, illustrative embodiments andexamples described herein provide a highly customizable anti-microbialmaterial, allowing use of complex decorative graphics and/or patternswhile maintaining full anti-microbial coverage.

No known system or device can perform these functions, particularly in amaterial with low flammability, low vapor permeability, and strongresistance to weathering and staining. However, not all embodiments andexamples described herein provide the same advantages or the same degreeof advantage.

Conclusion

The disclosure set forth above may encompass multiple distinct exampleswith independent utility. Although each of these has been disclosed inits preferred form(s), the specific examples thereof as disclosed andillustrated herein are not to be considered in a limiting sense, becausenumerous variations are possible. To the extent that section headingsare used within this disclosure, such headings are for organizationalpurposes only. The subject matter of the disclosure includes all noveland nonobvious combinations and subcombinations of the various elements,features, functions, and/or properties disclosed herein. The followingclaims particularly point out certain combinations and subcombinationsregarded as novel and nonobvious. Other combinations and subcombinationsof features, functions, elements, and/or properties may be claimed inapplications claiming priority from this or a related application. Suchclaims, whether broader, narrower, equal, or different in scope to theoriginal claims, also are regarded as included within the subject matterof the present disclosure.

What is claimed is:
 1. A decorative laminate comprising: a first laminate layer containing an anti-microbial agent; a second laminate layer; and a decorative layer disposed selectively between the first laminate layer and the second laminate layer; wherein the first laminate layer and the second laminate layer each comprise a thermoplastic fluoropolymer material, and wherein the first laminate layer, the decorative layer, and the second laminate layer are laminated together to form the decorative laminate configured for application to a structural component.
 2. The decorative laminate of claim 1 further comprising an adhesive layer disposed between the decorative laminate and a bonding surface of the structural component.
 3. The decorative laminate of claim 1 further comprising one or more additional laminate layers adjacent a first side of the decorative laminate layer.
 4. The decorative laminate of claim 1 further comprising one or more additional laminate layers adjacent a second side of the decorative laminate layer.
 5. The decorative laminate of claim 1 wherein the decorative laminate layer includes one or more materials deposited in an alignment pattern that facilitates alignment of the decorative laminate when applied to the structural component.
 6. The decorative laminate of claim 1 wherein the decorative laminate includes one or more of an ink jet printed ink, a silk screen printed ink, a pigment-based ink, a dye-based ink, a paint, a stain, and a digital printed ink.
 7. The decorative laminate of claim 1 wherein the anti-microbial agent is powdered silver dispersed within the first laminate layer.
 8. The decorative laminate of claim 1 wherein the anti-microbial agent includes at least one of a bacteriostatic agent, a fungistatic agent, an antibiotic agent, a fungicide, or a combination thereof.
 9. The decorative laminate of claim 1 wherein the decorative layer includes a resin layer disposed on the second laminate, and wherein the resin layer includes one or more thermoset resin materials.
 10. The decorative laminate of claim 1 wherein the structural component comprises a building interior structural component, a building structural composite panel, an aircraft interior structural component, a rotorcraft interior structural component, a spacecraft interior structural component, a watercraft interior structural component, an automobile interior structural component, or a truck interior structural component.
 11. A decorative laminate system comprising: a structural component having a bonding surface; a decorative laminate applied to the bonding surface of the structural component, the decorative laminate comprising: a first laminate layer having a transparent appearance and containing an anti-microbial agent; a second laminate layer having an opaque appearance, the first laminate layer and the second laminate layer each comprising a thermoplastic fluoropolymer material; a decorative layer disposed between the first laminate layer and the second laminate layer; a resin layer disposed on the second laminate layer; and an adhesive layer disposed between the decorative laminate and the bonding surface of the structural component.
 12. The decorative laminate system of claim 11 wherein the decorative laminate further comprises one or more additional laminate layers adjacent either a first side of the resin layer or a second side of the resin layer.
 13. The decorative laminate system of claim 11 wherein the decorative layer includes one or more of an ink jet printed ink, a silk screen printed ink, a pigment-based ink, a dye-based ink, a paint, a stain, and a digital printed ink.
 14. The decorative laminate system of claim 11 wherein the anti-microbial agent is either a powdered metal or a phenolic.
 15. The decorative laminate system of claim 11 wherein the anti-microbial agent includes at least one of a bacteriostatic agent, a fungistatic agent, an antibiotic agent, a fungicide, or a combination thereof.
 16. A vehicle, comprising: a structural component; and a decorative laminate applied to the structural component, the decorative laminate including: a first laminate layer containing an anti-microbial agent; a second laminate layer; and a decorative layer disposed selectively between the first laminate layer and the second laminate layer; wherein the first laminate layer and the second laminate layer each comprise a thermoplastic fluoropolymer material, and wherein the first laminate layer, the decorative layer, and the second laminate layer are laminated together to form the decorative laminate.
 17. The vehicle of claim 16 wherein the anti-microbial agent is either a powdered metal or a phenolic.
 18. The vehicle of claim 16 wherein the anti-microbial agent includes a bacteriostatic agent, a fungistatic agent, an antibiotic agent, a fungicide, or a combination thereof.
 19. The vehicle of claim 16 further comprising a light source, and wherein the decorative layer includes one or more visible materials and one or more non-visible light activated materials that change from a non-visible state to a visible state when exposed to light emitted from the light source.
 20. The vehicle of claim 16 wherein the decorative laminate layer includes one or more materials deposited in an alignment pattern that facilitates alignment of the decorative laminate when applied to the structural component. 